Mr. Vishal Narayanaswamy, Founder, EGGcellent EGGstender, Chennai, Tamil Nadu, talks about how to transform rotten eggs into golden eggs, an innovation in egg shelf life extension in India.
India is the third largest producer of eggs in the world with a bright future and a turnover of more than Rs. 1 lakh crores. It supports other industries like maize and soya farmers, eCommerce, and industries like ready to eat products. Products such as boiled eggs, ready to eat eggs are available in other countries, but in India, it is not much heard of. The problem starts when the eggs rotten, and all the states have this problem. Countries like Qatar and Oman have stopped eggs import from India due to this problem. There are lots of stories in the media about rotten eggs, and food waste in India is very high compared to other countries. When it comes to eggs, we need to understand the eggshell is not air tight like a plastic layer. There are lots of pores on the egg shell, and through them the bacteria, fungus, and other microbes enter the egg and spoil it.
The shell works as a barrier against a lot of microbes handling damages and wastes, and we are trying to control the microbes and environmental conditions to protect the eggs. The causes of egg spoilage are many such as faecal matter of the hen, flies sitting on the egg inside the egg farm, and once it is laid, in turn gives room for microbial spoilage and such things like that. There are many ways to protect egg spoilage such as keeping in the fridge. We can use organic substances that are harmless, cost-effective which can be applied and sealed in large farms. They are also spraying H2O2 to disinfect the egg outside. We are working on different methods. A study by Dr. Gururam Srinivas in 2020 talks about the poultry products and facts that affect the egg shell quality. The quality of the eggshell varies based on the type of food being fed to the chicken. It is difficult to control because the farmers are trying to cut cost due to market forces. The age of the bird also affects the egg shell quality. The egg would also vary from farm to farm. If these things are not controlled properly, the eggshell is weak, and egg becomes suitable for invasion for microorganism such as rotten mold. Washing the egg actually causes a bigger problem because it removes a layer called bloom which is a natural membrane on the top of the egg shell to protect the egg against microorganism. The deterioration is closely related to CO2 and increases the alkalinity of the egg. The loss of CO2 has to be prevented.
The main method to extend the shelf life of the egg is to reduce the CO2 by refrigeration, and it is costing roughly 15 to 20 paise per egg per month. Washing and sanitising remove the natural protective cuticle called bloom. In USA, they wash the eggs before keeping in the refrigeration unit or cold rooms, in Europe they don’t wash as they want to maintain the bloom which is the protective cuticle over the shell. In USA, they coat the egg with mineral oil to seal the pores and increase the shelf life of the egg by a week. Pasteurisation is another process where they heat the egg in water at 42 degree for 2 to 3 minutes so that the egg is not cooked. In this method, eggs are expensive, eggs are being packaged using vacuum packing and Modified Atmosphere Packaging to extend the shelf life which works out expensive in India. There are clean production practices, liming, or water glassing which are not scalable. We cannot use this in a farm which gets about 75 thousand eggs a day due to lack of space. So, we wanted to get a product which is 100% natural and is made from natural things such as curry leaf plant, berries, seaweed extract, pectin which is a starch, we are using things like Kefir and Zein from corn kernel and shellac used in food coating. We mixed some of these things and formed our own layer into which the egg can be dipped and taken out to extend the shelf life of egg for 30 days. The two tests of heating them at 42 degrees and 3 to 6 degrees show no microorganisms growing in the egg. There has been no test that has passed this level of parameters in the world. We have tested the solution for heavy metals, pesticides and microorganisms. The solution is certified under section 99 of FSSAI which handles things such as thickening agent, stabiliser, and gelling agent.
Coming to the cost, this is currently less than 3 paise per egg, and we are constantly working on reducing the cost. depending on the scale of how much we are able to scale, we can try to reduce the cost. The opportunity cost is the cold rooms which cost 15 to 20 paise per egg. This would be very sustainable as it does not use electricity. The cost of coating one egg is 0.5% of the market price of 4.5 Rs per egg. The brands are selling eggs for Rs. 15 per egg and the cost of this solution will only be 0.1% of their selling price.. The benefit of using a product like this would be to reduce food waste because we can extend the shelf life of the eggs, save money, and instead of throwing away or selling at a low price, the eggs can be sent to remote areas which could not be done before. It will also help preserve the quality for expert purposes. The countries that rejected our eggs can give a chance and try the products. The consumers are also benefited as they don’t have to buy eggs to be consumed immediately within a few days. They can keep them for 2 weeks. There are more business opportunities, people can start new products like boiled eggs to sell in supermarkets, coat and sell them there. It is also energy efficient as we can store the eggs when the price is low and sell them when the prices go up. Our product would definitely help companies like Swiggy and Zomato to maintain their quality.
Freshness is everything we need in the world of egg production and ensure that the consumers receive the best. With just one quick dip, we can transform the eggs, remove the risk of spoilage, food waste, and loss. There is no more concern about the egg getting spoilt. The reputation of quality is unbeatable, earn consumer trust, and prevent food borne illnesses. We ensure every egg is as fresh as on the day it was laid for up to 30 days.
How do these preservation techniques maintain or enhance the nutrition value and safety of eggs during extended storge periods?
What it does is, when the egg is dipped in the solution, it forms a thick layer of coating that is odourless, colourless, and you cannot even touch or feel it. It forms a thick layer of membrane that blocks the pores and does not allow any microorganisms to enter into the egg. Also, the carbon di oxide trapped inside the egg when it is laid is not allowed to escape, thereby reducing the rate of spoilage of the egg.
What challenges have you encountered in implementing the innovative preservation methods in Indian context, particularly concerning the local climatic conditions and storage infrastructure?
When we started this project, we noticed that since it was a liquid solution, we had to transport it in barrels that led to higher cost. We wanted to reduce the cost to benefit others. So, we converted the liquid into a powder from which is easy to transport. The farmers can fill water in a barrel, add the powder, and mix it. This was the first challenge we faced. Next was the Indian climate where in places that produced more number of eggs the temperature was very high. So, we want to build a product that can withstand the harsh climates of India, extend the shelf life of eggs, and all countries can benefit by this.
Are consumers in India willing to adapt new egg preservation techniques? Are there any government initiatives or subsidies supporting egg storage innovations?
People are investing a lot of money in infrastructure, cold rooms, and other methods, they spend a lot to store eggs. That infrastructure is going to cost a lot of money to store, the cooperating cost of each egg raises. Already people are spending money to preserve eggs. So We are trying to get another alternative method which is cost effective, cheaper, and a different way of preserving eggs. This is far less expensive compared to the current method they are using. I am not aware of this. We took part in the Poultry Tech Hackathon which was held in Coimbatore in January, and we got he first place. I was introduced to the judges, and many people there helped me in many ways to connect to the egg farmers, meet them, conduct trials on the ground before we launched the product. There is no government subsidy as such, but when we manufacture and sell something for 3 to 4 paise per egg, I think that itself is good and there is no need for any subsidy at this point.
How do your solutions address the unique needs of small scale poultry farmers in India, and what are the strategies in place to make them accessible and cost effective for them? How do you ensure compliance with food safety regulations and quality standards in the preservation process?
Our aim is to reduce the price for the eggs because earlier it was 7.5 paise per egg. But now, by converting the liquid into powder form, we are able to sell it at a cheaper rate costing about 4 to 4.5 paise per egg for the farmers. When we hit the scale, we will be able to get raw materials at a cheaper rate, and we can pass on those savings to the farmers. My target is to hit between 2 to 3 paise per egg. It will be the best way to help the farmers in India. We want to sell the powder in small sachets which can be procured easily from agriculture shops near the small farms. They should be able to use it as per the instructions. So a sachet of this powder can help in extending the shelf life of the eggs which is highly helpful to the farmers. We ensure that whatever raw materials we buy they are of food grade, conduct random test on it, and we use only SS machinery. It can be stored for over a year. Once the farmers mix the powder in the water, dip the eggs, they can store them for a long time. There is not much problem of eggs getting rotten. I don’t advise anyone to mix the powder until they are going to use it immediately.
Are there any collaborations or partnerships with research institutions, industry players, or international organisations by way of contribution to the development and implementation of this technology? How do you address consumer perceptions and acceptance of eggs that have undergone advanced preservation techniques?
We have not collaborated with anyone, and we are trying to work on this. I am currently discussing with International Institute of Biotechnology and Toxicology, for further studies. We have shown the product to them and described to them. They are seeing if more tests and papers and studies can be done on this. More people are asking if the solution can be used to extend the shelf life of fruits and vegetables, fish, and meat. Consumers should be happy that a brand is using this and prefer to buy from this brand as eggs will not be spoilt. We have to educate the customers. Many companies feel the consumers need not know about this as they cannot feel or see it. I feel it depends on their supply chain and managing the brand image.
What challenges have you faced in scaling your operations since your establishment?
We have not started fully selling this product and so no thought of scaling. I don’t think there will be any problem in operations. We have to educate the farmers which will be troublesome. Most of the large farms have expressed interest as they sell on quick commerce platforms. When they mix the eggs with other products, temperature not maintained, and not following the P4 practices, then eggs may go rotten. So, this coating would prevent the brand from getting a bad name. The problem will be from uneducated farmers in making them understand the concept.
Please tell us about yourself and how you got interested in this.
I am not from an egg background. I was running a B2C hydroponics vegetable delivery company, Gourmet Garden. We found that 70 to 90 lakhs rupees worth fruits and vegetables were wasted. We tried many things such as shellac to extend the life of fruits and vegetables. Then I came out of the company, and I continued with extension of shelf life techniques. I found out a certain mix of products actually worked better for eggs. Then I got the product tested by lab, as people who wanted to buy it were keen about certification from a lab. Many farmers and farm owners are supportive of me by suggesting where to get it tested, what test to be done, and how to go about the process. I want to get a solution for the farmers that is cheap, affordable, and it has been an interesting journey so far.
Vishal Narayanaswamy
Founder
EGGcellent EGGstender
Dr.B.P. Rajan Road, Uthandi, ECR
Chennai, Tamil Nadu 600119.
Email: vishal@group24.in
Phone: 9551336335
India is the third largest producer of eggs in the world with a bright future and a turnover of more than Rs. 1 lakh crores. It supports other industries like maize and soya farmers, eCommerce, and industries like ready to eat products. Products such as boiled eggs, ready to eat eggs are available in other countries, but in India, it is not much heard of. The problem starts when the eggs rotten, and all the states have this problem. Countries like Qatar and Oman have stopped eggs import from India due to this problem. There are lots of stories in the media about rotten eggs, and food waste in India is very high compared to other countries. When it comes to eggs, we need to understand the eggshell is not air tight like a plastic layer. There are lots of pores on the egg shell, and through them the bacteria, fungus, and other microbes enter the egg and spoil it.
The shell works as a barrier against a lot of microbes handling damages and wastes, and we are trying to control the microbes and environmental conditions to protect the eggs. The causes of egg spoilage are many such as faecal matter of the hen, flies sitting on the egg inside the egg farm, and once it is laid, in turn gives room for microbial spoilage and such things like that. There are many ways to protect egg spoilage such as keeping in the fridge. We can use organic substances that are harmless, cost-effective which can be applied and sealed in large farms. They are also spraying H2O2 to disinfect the egg outside. We are working on different methods. A study by Dr. Gururam Srinivas in 2020 talks about the poultry products and facts that affect the egg shell quality. The quality of the eggshell varies based on the type of food being fed to the chicken. It is difficult to control because the farmers are trying to cut cost due to market forces. The age of the bird also affects the egg shell quality. The egg would also vary from farm to farm. If these things are not controlled properly, the eggshell is weak, and egg becomes suitable for invasion for microorganism such as rotten mold. Washing the egg actually causes a bigger problem because it removes a layer called bloom which is a natural membrane on the top of the egg shell to protect the egg against microorganism. The deterioration is closely related to CO2 and increases the alkalinity of the egg. The loss of CO2 has to be prevented.
The main method to extend the shelf life of the egg is to reduce the CO2 by refrigeration, and it is costing roughly 15 to 20 paise per egg per month. Washing and sanitising remove the natural protective cuticle called bloom. In USA, they wash the eggs before keeping in the refrigeration unit or cold rooms, in Europe they don’t wash as they want to maintain the bloom which is the protective cuticle over the shell. In USA, they coat the egg with mineral oil to seal the pores and increase the shelf life of the egg by a week. Pasteurisation is another process where they heat the egg in water at 42 degree for 2 to 3 minutes so that the egg is not cooked. In this method, eggs are expensive, eggs are being packaged using vacuum packing and Modified Atmosphere Packaging to extend the shelf life which works out expensive in India. There are clean production practices, liming, or water glassing which are not scalable. We cannot use this in a farm which gets about 75 thousand eggs a day due to lack of space. So, we wanted to get a product which is 100% natural and is made from natural things such as curry leaf plant, berries, seaweed extract, pectin which is a starch, we are using things like Kefir and Zein from corn kernel and shellac used in food coating. We mixed some of these things and formed our own layer into which the egg can be dipped and taken out to extend the shelf life of egg for 30 days. The two tests of heating them at 42 degrees and 3 to 6 degrees show no microorganisms growing in the egg. There has been no test that has passed this level of parameters in the world. We have tested the solution for heavy metals, pesticides and microorganisms. The solution is certified under section 99 of FSSAI which handles things such as thickening agent, stabiliser, and gelling agent.
Coming to the cost, this is currently less than 3 paise per egg, and we are constantly working on reducing the cost. depending on the scale of how much we are able to scale, we can try to reduce the cost. The opportunity cost is the cold rooms which cost 15 to 20 paise per egg. This would be very sustainable as it does not use electricity. The cost of coating one egg is 0.5% of the market price of 4.5 Rs per egg. The brands are selling eggs for Rs. 15 per egg and the cost of this solution will only be 0.1% of their selling price.. The benefit of using a product like this would be to reduce food waste because we can extend the shelf life of the eggs, save money, and instead of throwing away or selling at a low price, the eggs can be sent to remote areas which could not be done before. It will also help preserve the quality for expert purposes. The countries that rejected our eggs can give a chance and try the products. The consumers are also benefited as they don’t have to buy eggs to be consumed immediately within a few days. They can keep them for 2 weeks. There are more business opportunities, people can start new products like boiled eggs to sell in supermarkets, coat and sell them there. It is also energy efficient as we can store the eggs when the price is low and sell them when the prices go up. Our product would definitely help companies like Swiggy and Zomato to maintain their quality.
Freshness is everything we need in the world of egg production and ensure that the consumers receive the best. With just one quick dip, we can transform the eggs, remove the risk of spoilage, food waste, and loss. There is no more concern about the egg getting spoilt. The reputation of quality is unbeatable, earn consumer trust, and prevent food borne illnesses. We ensure every egg is as fresh as on the day it was laid for up to 30 days.
How do these preservation techniques maintain or enhance the nutrition value and safety of eggs during extended storge periods?
What it does is, when the egg is dipped in the solution, it forms a thick layer of coating that is odourless, colourless, and you cannot even touch or feel it. It forms a thick layer of membrane that blocks the pores and does not allow any microorganisms to enter into the egg. Also, the carbon di oxide trapped inside the egg when it is laid is not allowed to escape, thereby reducing the rate of spoilage of the egg.
What challenges have you encountered in implementing the innovative preservation methods in Indian context, particularly concerning the local climatic conditions and storage infrastructure?
When we started this project, we noticed that since it was a liquid solution, we had to transport it in barrels that led to higher cost. We wanted to reduce the cost to benefit others. So, we converted the liquid into a powder from which is easy to transport. The farmers can fill water in a barrel, add the powder, and mix it. This was the first challenge we faced. Next was the Indian climate where in places that produced more number of eggs the temperature was very high. So, we want to build a product that can withstand the harsh climates of India, extend the shelf life of eggs, and all countries can benefit by this.
Are consumers in India willing to adapt new egg preservation techniques? Are there any government initiatives or subsidies supporting egg storage innovations?
People are investing a lot of money in infrastructure, cold rooms, and other methods, they spend a lot to store eggs. That infrastructure is going to cost a lot of money to store, the cooperating cost of each egg raises. Already people are spending money to preserve eggs. So We are trying to get another alternative method which is cost effective, cheaper, and a different way of preserving eggs. This is far less expensive compared to the current method they are using. I am not aware of this. We took part in the Poultry Tech Hackathon which was held in Coimbatore in January, and we got he first place. I was introduced to the judges, and many people there helped me in many ways to connect to the egg farmers, meet them, conduct trials on the ground before we launched the product. There is no government subsidy as such, but when we manufacture and sell something for 3 to 4 paise per egg, I think that itself is good and there is no need for any subsidy at this point.
How do your solutions address the unique needs of small scale poultry farmers in India, and what are the strategies in place to make them accessible and cost effective for them? How do you ensure compliance with food safety regulations and quality standards in the preservation process?
Our aim is to reduce the price for the eggs because earlier it was 7.5 paise per egg. But now, by converting the liquid into powder form, we are able to sell it at a cheaper rate costing about 4 to 4.5 paise per egg for the farmers. When we hit the scale, we will be able to get raw materials at a cheaper rate, and we can pass on those savings to the farmers. My target is to hit between 2 to 3 paise per egg. It will be the best way to help the farmers in India. We want to sell the powder in small sachets which can be procured easily from agriculture shops near the small farms. They should be able to use it as per the instructions. So a sachet of this powder can help in extending the shelf life of the eggs which is highly helpful to the farmers. We ensure that whatever raw materials we buy they are of food grade, conduct random test on it, and we use only SS machinery. It can be stored for over a year. Once the farmers mix the powder in the water, dip the eggs, they can store them for a long time. There is not much problem of eggs getting rotten. I don’t advise anyone to mix the powder until they are going to use it immediately.
Are there any collaborations or partnerships with research institutions, industry players, or international organisations by way of contribution to the development and implementation of this technology? How do you address consumer perceptions and acceptance of eggs that have undergone advanced preservation techniques?
We have not collaborated with anyone, and we are trying to work on this. I am currently discussing with International Institute of Biotechnology and Toxicology, for further studies. We have shown the product to them and described to them. They are seeing if more tests and papers and studies can be done on this. More people are asking if the solution can be used to extend the shelf life of fruits and vegetables, fish, and meat. Consumers should be happy that a brand is using this and prefer to buy from this brand as eggs will not be spoilt. We have to educate the customers. Many companies feel the consumers need not know about this as they cannot feel or see it. I feel it depends on their supply chain and managing the brand image.
What challenges have you faced in scaling your operations since your establishment?
We have not started fully selling this product and so no thought of scaling. I don’t think there will be any problem in operations. We have to educate the farmers which will be troublesome. Most of the large farms have expressed interest as they sell on quick commerce platforms. When they mix the eggs with other products, temperature not maintained, and not following the P4 practices, then eggs may go rotten. So, this coating would prevent the brand from getting a bad name. The problem will be from uneducated farmers in making them understand the concept.
Please tell us about yourself and how you got interested in this.
I am not from an egg background. I was running a B2C hydroponics vegetable delivery company, Gourmet Garden. We found that 70 to 90 lakhs rupees worth fruits and vegetables were wasted. We tried many things such as shellac to extend the life of fruits and vegetables. Then I came out of the company, and I continued with extension of shelf life techniques. I found out a certain mix of products actually worked better for eggs. Then I got the product tested by lab, as people who wanted to buy it were keen about certification from a lab. Many farmers and farm owners are supportive of me by suggesting where to get it tested, what test to be done, and how to go about the process. I want to get a solution for the farmers that is cheap, affordable, and it has been an interesting journey so far.
Vishal Narayanaswamy
Founder
EGGcellent EGGstender
Dr.B.P. Rajan Road, Uthandi, ECR
Chennai, Tamil Nadu 600119.
Email: vishal@group24.in
Phone: 9551336335
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